Electrode materials with high surface conductivity

ABSTRACT

The present invention concerns electrode materials capable of redox reactions by electron and alkali-ion exchange with an electrolyte. The applications are in the field of primary (batteries) or secondary electrochemical generators, supercapacitors and light modulating systems of the electrochromic type.

The present application is a continuation of U.S. patent applicationSer. No. 12/951,335, filed Nov. 22, 2010, which is a continuation ofU.S. patent application Ser. No. 12/033,636, filed Feb. 19, 2008 (nowU.S. Pat. No. 7,815,819), which is a divisional of U.S. patentapplication Ser. No. 11/266,339, filed Nov. 4, 2005 (now U.S. Pat. No.7,344,659), which is a continuation of U.S. application Ser. No.10/740,449 filed Dec. 22, 2003, (now U.S. Pat. No. 6,962,666), which isa divisional of U.S. application Ser. No. 10/175,794, filed Jun. 21,2002 (now U.S. Pat. No. 6,855,273), which is a continuation of U.S.application Ser. No. 09/560,572, filed Apr. 28, 2000, now abandoned,which claims the benefit of CA 2,270,771, filed Apr. 30, 1999. Theentire contents of which are hereby incorporated herein by reference.

FIELD OF INVENTION

The present invention concerns electrode materials capable of redoxreactions by electron and alkali-ion exchange with an electrolyte. Theapplications are in the field of primary (batteries) or secondaryelectrochemical generators, supercapacitors and light modulating systemsof the electrochromic type.

BACKGROUND OF THE INVENTION

Insertion compounds (hereinafter also referred to as electroactivematerials or redox materials) are well known, and their operation isbased on the exchange of alkali ions, in particular lithium ions, andvalence electrons of at least one transition element, in order to keepthe neutrality of the solid matrix. The partial or complete maintenanceof the structural integrity of the material allows the reversibility ofthe reaction. Redox reactions resulting in the formation of severalphases are usually not reversible, or only partially. It is alsopossible to perform the reactions in the solid phase through thereversible scission of the sulphur-sulphur bonds or the redox reactionsinvolved in the transformation of the aromatic organic structures inquinonoid form, including in conjugated polymers.

The insertion materials are the electrochemical reactions activecomponents used, in particular, in electrochemical generators,supercapacitors or light transmission modulating systems (electrochromicdevices).

The progression of the ions-electrons exchange reaction requires theexistence within the insertion material of a double conductivity,simultaneous with the electrons and the ions, in particular lithiumions, either one of these conductivities which may be too weak to ensurethe necessary kinetic exchanges for the use of the material, inparticular for electrochemical generators or supercapacitors. Thisproblem is partly solved by using so-called “composite” electrodes,wherein the electrode material is dispersed in a matrix containing theelectrolyte and a polymer binder. When the electrolyte is a polymerelectrolyte or a polymer gel working in the presence of a solvent, themechanical binding role is carried out directly by the macromolecule.Gel means a polymer matrix, solvating or not, and retaining a polarliquid and a salt, to confer to the mixture the mechanical properties ofa solid while retaining at least a part of the conductivity of the polarliquid. A liquid electrolyte and the electrode material can also bemaintained in contact with a small fraction of an inert polymer binder,i.e., not interacting with the solvent. With any of these means, eachelectrode material particle is thus surrounded by an electrolyte capableof bringing the ions in direct contact with almost the totality of theelectrode material surface. To facilitate electronic exchanges, it iscustomary, according to the prior art, to add particles of a conductivematerial to one of the mixtures of the electrode material andelectrolyte mentioned above. Such particles are in a very divided state.Generally, carbon-based materials are selected, and especially carbonblacks (Shawinigan or Ketjenblack®). However, the volume fractions usedmust be kept low because such material strongly modifies the rheology oftheir suspension, especially in polymers, thereby leading to anexcessive porosity and loss of operating efficiency of the compositeelectrode, in terms of the fraction of the usable capacity as well asthe kinetics, i.e., the power available. At these low concentrationsused, the carbon particles structure themselves in chains, and thecontact points with the electrode materials are extremely reduced.Consequently, such configuration results in a poor distribution of theelectrical potential within the electroactive material. In particular,over-concentrations or depletion can appear at the triple junctionpoints:

These excessive variations of the mobile ions local concentrations andthe gradients within the electroactive materials are extremelyprejudicial to the reversibility of the electrode operation over a highnumber of cycles. These chemical and mechanical constraints or stressesresult, at the microscopic level, in the disintegration (particulation)of the electroactive material particles, a part of which becomesusceptible to losing contact with the carbon particles and thusbecoming electrochemically inactive. The material structure can also bedestroyed, with the appearance of new phases and possible release oftransition metal derivatives, or other fragments in the electrolyte.These harmful phenomenons appear even more easily the larger the currentdensity or the power requested at the electrode is.

IN THE DRAWINGS

FIG. 1 illustrates the difference between a classic electrode accordingto the prior art (A) and an electrode according to the invention whereinthe electroactive material particles are coated with a carbonaceouscoating (B).

FIGS. 2 and 3 illustrate a comparison between a sample of LiFePO₄ coatedwith a carbonaceous deposit, and an uncoated sample. The results wereobtained by cyclic voltammetry of LiFePO₄/POE₂₀LiTFSI/Li batteriescycled at 20 mV·h⁻¹ between 3 and 3.7 V at 80° C. The first cycle isshown in FIG. 2, and the fifth in FIG. 3.

FIG. 4 illustrates the evolution of capacity during cycling forbatteries containing carbonaceous and non-carbonaceous LiFePO₄ samples.

FIG. 5 illustrates the performances of a battery containing carbonaceousLiFePO₄ and cycled under an intentiostatic mode between 3 and 3.8 V at80° C. with a charge and discharge speed corresponding to C/1.

FIG. 6 illustrates the evolution of the current vs. time of aLiFePO₄/gamma-butyrolactone LiTFSI/Li containing a carbonaceous sampleand cycled at 20 mV·h⁻¹ between 3 and 3.7 V at room temperature.

FIG. 7 illustrates the evolution of the current vs. time of aLiFePO₄/POE₂₀LiTFSI/Li containing a carbonaceous sample.

FIGS. 8 and 9 illustrate a comparison between carbonaceous andnon-carbonaceous LiFePO₄ samples, cycled. The results have been obtainedby cyclic voltammetry of LiFePO₄/POE₂₀LiTFSI/Li batteries cycled at 20mV·h⁻¹ between 3 and 3.7 V at 80° C. The first cycle is shown in FIG. 8,and the fifth in FIG. 9.

FIG. 10 illustrates the evolution of the capacity during cycling ofbatteries prepared with carbonaceous and non-carbonaceous LiFePO₄samples.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided an electrodematerial comprising a complex oxide corresponding to the general formulaA_(a)M_(m)Z_(z)O_(o)N_(n)F_(f) wherein:

A comprises an alkali metal;

M comprises at least one transition metal, and optionally at least onenon-transition metal such as magnesium or aluminum; and mixturesthereof;

Z comprises at least one non-metal;

O is oxygen, N is nitrogen and F is fluorine; and

the coefficients a, m, z, o, n, f≧0 and are selected to ensureelectroneutrality, wherein a conductive carbonaceous material isdeposited homogeneously on a surface of the material to obtain asubstantially regular electric field distribution on the surface ofmaterial particles. The similarity in ionic radii between oxygen,fluorine and nitrogen allows mutual replacement of these elements aslong as electroneutrality is maintained. For simplicity, and consideringthat oxygen is the most frequently used element, these materials arehereinafter referred to as complex oxides. Preferred transition metalscomprise iron, manganese, vanadium, titanium, molybdenum, niobium,tungsten, zinc and mixtures thereof. Preferred non-transition metalscomprise magnesium and aluminum, and preferred non-metals comprisesulfur, selenium, phosphorous, arsenic, silicon, germanium, boron, andmixtures thereof

In a preferred embodiment, the final mass concentration of thecarbonaceous material varies between 0.1 and 55%, and more preferablybetween 0.2 and 15%.

In a further preferred embodiment, the complex oxide comprises sulfates,phosphates, silicates, oxysulfates, oxyphosphates, and oxysilicates of atransition metal and lithium, and mixtures thereof. It may also be ofinterest, for structural stability purposes, to partially replace thetransition metal with an element having the same ionic radius, but notinvolved in the redox process. For example, magnesium and aluminum, inconcentrations preferably varying between 1 and 25%, may be used.

The present invention also concerns electrochemical cells wherein atleast one electrode is made of an electrode material according to thepresent invention. The cell can operate as a primary or secondarybattery, a supercapacitor, or a light modulating system, the primary ora secondary battery being the preferred mode of operation.

DETAILED DESCRIPTION OF THE INVENTION

The present invention allows the fabrication of electrode materials ofextremely varied compositions with its surface, or most of it, coatedwith a uniform coating of a conductive carbonaceous material depositedchemically. The presence in the electrode materials of the invention ofa uniform coating, when compared to contact points obtained with carbonpowders or other prior art conductive additives, allows a regulardistribution of the electrical field at the surface of the electroactivematerial particles. Further, the ion concentration gradients areconsiderably diminished. Such improved distribution of theelectrochemical reaction at the surface of the particles allows, on oneside, the maintenance of the structural integrity of the material, andon the other side, improves the kinetics in terms of the current densityand power availability at the electrode, because of the greater surfaceaccessibility.

In the present application, carbonaceous material means a solid polymercomprising mainly carbon, i.e., from 60 to 100% molar, and having anelectronic conductivity higher than 10⁻⁶ S/cm at room temperature,preferably higher than 10⁻⁴ S/cm. Other elements that can be present arehydrogen, oxygen, and nitrogen, as long as they do not interfere withthe chemical inertia of the carbon during the electrochemical operation.The carbonaceous material can be obtained through thermal decompositionor dehydrogenation, e.g., by partial oxidation, of various organicmaterials. In general, any material leading, through a reaction or asequence of reactions, to the solid carbonaceous material with thedesired property without affecting the stability of the complex oxide isa suitable precursor. Preferred precursors include, but are not limitedto: hydrocarbons and their derivatives, especially those comprisingpolycyclic aromatic moieties, like pitch and tar derivatives; peryleneand its derivatives; polyhydric compounds like sugars and carbonhydrates and their derivatives; and polymers. Preferred examples of suchpolymers include polyolefins, polybutadienes, polyvinylic alcohol,phenol condensation products, including those from a reaction with analdehyde, polymers derived from furfurylic alcohol, polymer derivativesof styrene, divinylbenzene, naphthalene, perylene, acrylonitrile, vinylacetate, cellulose, starch and their esters and ethers, and mixturesthereof

The improvement of the conductivity at the surface of the particlesobtained with the carbonaceous material coating according to the presentinvention allows the satisfactory operation of electrodes containingelectroactive materials having an insufficient electronic conductivityto obtain acceptable performances. Complex oxides with redox couples ina useful voltage range and/or using inexpensive or nontoxic elements butwhose conductivity otherwise would be too low for practical use, nowbecome useful as electrode materials when the conductive coating ispresent. The choice of the structures or phase mixtures possessing redoxproperties but having an electronic conductivity that is too low, isthus much wider than that of compounds of the prior art. It is possibleto include within the redox structures, at least one element selectedfrom non-metals (metalloids) such as sulphur, selenium, phosphorus,arsenic, silicon or germanium, wherein the greater electronegativityallows the modulation of the redox potential of the transition elements,but at the expense of the electronic conductivity. A similar effect isobtained with the partial or complete substitution of the oxygen atomswith fluorine or nitrogen.

The redox materials are described by the general formulaA_(a)M_(m)Z_(z)O_(o)N_(n)F_(f) wherein:

A comprises an alkali metal such as Li, Na, or K;

M comprises at least one transition metal, and optionally at least onenon-transition metal such as magnesium or aluminum; or mixtures thereof;

Z comprises at least one non-metal such as S, Se, P, As, Si, Ge, B;

O is oxygen;

N is nitrogen and F is fluorine, wherein the latter elements can replaceoxygen in the complex oxide because the ionic radii values for F⁻, O²⁻and N³⁻ are similar; and

each coefficient a, m, z, o, n and f≧0 independently, to ensureelectroneutrality of the material.

Preferred complex oxides according to the invention comprise those offormula Li_(1+x)MP_(1-x)Si_(x)O₄; Li_(1+x-y)MP_(1-x)Si_(x)O_(4-y)F_(y);Li_(3-x+z)M₂(P_(1-x-z)S_(x)Si_(z)O₄)₃;Li_(3+u-x+z)V_(2-z-w)Fe_(u)Ti_(w)(P_(1-x-z) S_(x)Si_(z)O₄)₃, orLi_(4+x)Ti₅O₁₂, Li_(4+x-2y)Mg_(y)Ti₅O₁₂, wherein w≦2; 0≦x, y≦1; z≦1 andM comprises Fe or Mn.

The carbonaceous coating can be deposited through various techniquesthat are an integral part of the invention. A preferred method comprisesthe pyrolysis of organic matter, preferably carbon-rich, in the presenceof the redox material. Particularly advantageous are mesomolecules andpolymers capable of easily forming, either mechanically or byimpregnation from a solution or through in situ polymerization, auniform layer at the surface of the redox material particles. Asubsequent pyrolysis or dehydrogenation step thereof provides a fine anduniform layer of the carbonaceous material at the surface of theparticles of the redox material. To ensure that the pyrolysis ordehydrogenation reaction will not affect the latter, it is preferred toselect compositions wherein the oxygen pressure liberated from thematerial is sufficiently low to prevent oxidation of the carbon formedby the pyrolysis. The activity of the oxygen of compoundsA_(a)M_(m)Z_(z)O_(o)N_(n)F_(f) can be controlled by the concentration ofalkali metal, which itself determines the oxidation state of thetransition element or elements contained in the material and being apart of the invention. Of particular interest are the compositionswherein the coefficient “a” of the alkali metal concentration allows themaintenance of the following oxidation states: Fe²⁺, Mn²⁺, V²⁺, V³⁺,Ti²⁺, Ti³⁺, Mo³⁺, Mo⁴⁺, Nb³⁺, Nb⁴⁺, W⁴⁺. Generally, oxygen pressures onthe order of 10⁻²⁰ bars at 0° C. and of 10⁻¹⁰ bars at 900° C. aresufficiently low to allow the deposition of carbon by pyrolysis, thekinetics of carbon formation in the presence of hydrocarbonaceousresidues resulting from the pyrolysis being quicker and less activatedthan oxygen formation from the redox materials. It is also possible andadvantageous to select materials having an oxygen pressure inequilibrium with the materials that are inferior to that of theequilibrium:

C+O₂

CO₂

In this instance, the carbonaceous material can be thermodynamicallystable vis-á-vis the complex oxide. The corresponding pressures areobtained according to the following equation:

${\ln \mspace{14mu} {P\left( O_{2} \right)}} = {{\ln \mspace{14mu} {P\left( {CO}_{2} \right)}} = \frac{94050}{R\left( {273.2 + \theta} \right)}}$

wherein R is the perfect gas constant (1.987 cal·mole⁻¹·K⁻¹); andθ is the temperature in ° C.

Table 1 provides oxygen pressures at several temperatures:

P(O₂) P(O₂) θ (° C.) P(CO₂) = 1 atm P(CO₂) = 10⁻⁵ atm 200 3.5 × 10⁻⁴⁴3.5 × 10⁻⁴⁹ 300 1.4 × 10⁻³⁶ 1.4 × 10⁻⁴¹ 400 2.9 × 10⁻³¹ 2.9 × 10⁻³⁶ 5002.5 × 10⁻²⁷ 2.5 × 10⁻³² 600 2.9 × 10⁻²⁴ 2.5 × 10⁻²⁹ 700 7.5 × 10⁻²² 7.5× 10⁻²⁷ 800 7.0 × 10⁻²⁰ 7.0 × 10⁻²⁵ 900 3.0 × 10⁻¹⁸ 3.0 × 10⁻²³

It is also possible to perform the carbon deposition through thedisproportionation of carbon oxide at temperatures lower than 800° C.according to the equation:

2CO

C+CO₂

This reaction is exothermic but slow. The complex oxide particles can becontacted with carbon monoxide, pure or diluted in an inert gas, attemperatures varying from 100 to 750° C., preferably between 300 and650° C. Advantageously, the reaction is carried out in a fluidized bed,in order to have a large exchange surface between the gaseous phase andthe solid phase. Elements and cations of transition metals present inthe complex oxide are catalysts of the disproportionation reaction. Itcan be advantageous to add small amounts of transition metal salts,preferably iron, nickel, or cobalt, at the surface of the particles,these elements being particularly active as catalysts of thedisproportionation reaction. In addition to carbon monoxidedisproportionation, hydrocarbons in gaseous form can be decomposed atmoderate to high temperatures to yield carbon deposits. Of specialinterest for the operation are the hydrocarbons with a low energy offormation, like alkenes, alkynes or aromatic rings.

In a variation, the deposition of the carbonaceous material can beperformed simultaneously with a variation of the composition of alkalimetal A. To do so, an organic acid or polyacid salt is mixed with thecomplex oxide. Another possibility comprises the in situ polymerizationof a monomer or monomer mixtures. Through pyrolysis, the compounddeposits a carbonaceous material film at the surface and the alkalimetal A is incorporated according to the equation:

A_(a)′M_(m)Z_(z)O_(o)N_(n)F_(f)+A_(a-a)′C_(c)O_(o)R′

A_(a)M_(m)Z_(z)O_(o)N_(n)F_(f)

R′ being an organic radical, which may be part of a polymeric chain.

Compounds capable of permitting this reaction may include, but are notlimited to, salts of carboxylic acids such as oxalic, malonic, succinic,citric, polyacrylic, polymethacrylic, benzoic, phtalic, propiolic,acetylene dicarboxylic, naphthalene di- or tetracarboxylic, perylenetetracarboxylic and diphenic acids.

Obviously, the pyrolysis of an organic material deprived of an alkalielement in combination with an alkali element salt can also lead to thedesired stoichiometry of the complex oxide.

It is also possible to obtain a carbonaceous material deposit,especially at low or mid-range temperatures, lower than 400° C., byreduction of carbon-halogen bonds according to the equation:

CY—CY+2e ⁻

-C═C-+2Y⁻

wherein Y represents a halogen or a pseudo-halogen. The termpseudo-halogen means an organic or inorganic radical capable of existingin the form of an ion Y⁻ and forming a corresponding protonated compoundHY. Examples of halogen and pseudo-halogen include F, Cl, Br, I, CN,SCN, CNO, OH, N₃, RCO₂, RSO₃, wherein R is H or an organic radical. Theformation by reduction of CY bonds is preferably performed in thepresence of reducing elements such as hydrogen, zinc, magnesium, Ti³⁺ions, Ti²⁺ ions, Sm²⁺ ions, Cr²⁺ ions, V²⁺ ions, tetrakis(dialkylaminoethylene) or phosphines. These reagents can optionally be obtained orregenerated electrochemically. Further, it can also be advantageous touse catalysts to increase the reduction kinetics. Palladium or nickelderivatives are particularly efficient, particularly in the form ofcomplexes with phosphorous or nitrogen compounds like 2,2′-bipyridine.Similarly, these compounds can be generated chemically in an active formin the presence of reducing agents, such as those mentioned above, orelectrochemically. Compounds capable of generating carbon by reductioninclude perhalocarbons, particularly in the form of polymers,hexachlorobutadiene and hexachlorocyclopentadiene.

Another way to release carbon from a low temperature process comprisesthe elimination of the hydrogenated compound HY, Y being as definedabove, according to the equation:

—CH—CY-+B

—C═C-+BHY

Compounds capable of generating carbon from reduction include organiccompounds comprising an even number of hydrogen atoms and Y groups, suchas hydrohalocarbons, in particular in the form of polymers, such asvinylidene polyfluoride, polychloride or polybromide, or carbonhydrates. The dehydro (pseudo) halogenation can be obtained at lowtemperatures, including room temperature, by reacting a base with the HYcompound to form a salt. Examples of suitable bases include tertiarybases, amines, amidines, guanidines, imidazoles, inorganic bases such asalkali hydroxides, organometallic compounds behaving like strong bases,such as A(N(Si(CH₃)₃)₂, LiN[CH(CH₃)₂]₂, and butyl-lithium.

In the last two methods, it can be advantageous to anneal the materialafter the carbon deposition. Such treatment improves the structure orthe crystallinity of the carbonaceous deposit. The treatment can beperformed at a temperature varying between 100 and 1000° C., preferablybetween 100 and 700° C., to prevent the potential reduction of thecomplex oxide by the carbonaceous material.

Generally, it is possible to obtain uniform carbonaceous materialcoatings, ensuring a sufficient electronic conductivity, i.e., at leaston the same order as the ionic conductivity of the oxide particle. Thethick coatings provide a conductivity sufficient so that the binarymixture of complex oxide particles coated with the carbonaceousmaterial, and the liquid or polymeric electrolyte or the inertmacromolecular binder to be wetted with the electrolyte, is conductiveby a simple contact between the particles. Generally, such behavior canbe observed at volumic fractions comprised between 10 and 70%.

It can also be advantageous to select deposits of carbonaceous materialssufficiently thin to prevent obstruction of the passage of ions, whileensuring the distribution of the electrochemical potential at thesurface of the particles. In this instance, the binary mixtures possiblydo not possess an electronic conductivity sufficient to ensure theelectronic exchanges with the electrode substrate (current collector).The addition of a third electronic conductive component, in the form ofa fine powder or fibers, provides satisfactory macroscopic conductivityand improves the electronic exchanges with the electrode substrate.Carbon blacks or carbon fibers are particularly advantageous for thispurpose and give satisfactory results at volumic concentrations thathave little or no effect on the rheology during the use of the electrodebecause of the existence of electronic conductivity at the surface ofthe electrode material particles. Volumic fractions of 0.5 to 10% areparticularly preferred. Carbon black such as Shawinigan® or Ketjenblack®are preferred. Among carbon fibers, those obtained by pyrolysis ofpolymers, such as tar, pitch, polyacrylonitrile as well as thoseobtained by cracking of hydrocarbons, are preferred.

Interestingly, because of its light weight and malleability, aluminiumis used as the current collector constituent. This metal is nonethelesscoated with an insulating oxide layer. This layer, which protects themetal from corrosion, can in certain conditions increase the thickness,leading to an increased resistance of the interface, prejudicial to thegood operation of the electrochemical cell. This phenomenon can beparticularly detrimental and fast when the electronic conductivity isonly ensured, as in the prior art, by the carbon particles having alimited number of contact points. The use, in combination withaluminium, of electrode materials coated with a conductive carbonaceousmaterial layer increases the exchange surface aluminium-electrode. Thealuminium corrosion effects are therefore cancelled or at leastsignificantly minimized. It is possible to use either aluminiumcollectors in the form of a sheet or possibly in the form of expanded orperforated metal or fibers, which allow a weight gain. Because of theproperties of the materials of the invention, even in the case ofexpanded or perforated metal, electronic exchanges at the collectorlevel take place without a noticeable increase of the resistance.

Whenever the current collectors are thermally stable, it is alsopossible to perform the pyrolysis or dehydrogenation directly on thecollector so as to obtain, after carbon deposition, a continuous porousfilm that can be infiltrated with an ionic conductive liquid, or with amonomer or a mixture of monomers generating a polymer electrolyte afterin situ polymerization. The formation of porous films in which thecarbonaceous coating forms a chain is easily obtained according to theinvention through pyrolysis of a complex oxide-polymer compositedeposited in the form of a film on a metallic substrate.

In using the electrode material according to the invention in anelectrochemical cell, preferably a primary or secondary battery, theelectrolyte is preferably a polymer, solvating or not, optionallyplasticized or gelled by a polar liquid in which one or more metallicsalts, preferably at least a lithium salt, are dissolved. In suchinstance, the polymer is preferably formed from units of oxyethylene,oxypropylene, acrylonitrile, vinylidene fluoride, acrylic acid ormethacrylic acid esters, or itaconic acid esters with alkyls or oxaalkylgroups. The electrolyte can also be a polar liquid immobilized in amicroporous separator, such as a polyolefin, a polyester, nanoparticlesof silica, alumina or lithium aluminate (LiAlO₂). Examples of polarliquids include cyclic or linear carbonates, alkyl formiates,oligoethylene glycols, α-ω alkylethers, N-methylpyrrolidinone,γ-butyrolactone, tetraalakylsulfamides and mixtures thereof.

The following examples are provided to illustrate preferred embodimentsof the invention, and shall not be construed as limiting its scope.

Example 1

This example illustrates the synthesis of a material of the presentinvention leading directly to an insertion material coated with acarbonaceous deposit.

The material LiFePO₄ coated with a carbonaceous deposit is prepared fromvivianite (Fe₃(PO₄)₂.8H₂O) and lithium orthophosphate (Li₃PO₄) instoichiometric amounts according to the reaction:

Fe₃(PO₄)₂.8H₂O+Li₃PO₄

3LiFePO₄

Polypropylene powder in an amount corresponding to 3% by weight ofvivianite is added. The three components are intimately mixed togetherand ground in a zirconia ball mill. The mixture is then heated under aninert atmosphere of argon, first at 350° C. for 3 hours to dehydrate thevivianite. Subsequently, the temperature is gradually increased up to700° C. to crystallize the material and carbonize the polypropylene. Thetemperature is maintained at 700° C. for 7 hours. The structure of thematerial obtained, as verified by X-rays, corresponds to that publishedfor triphyllite. The amount of carbon present in the sample has beendetermined by elemental analysis, and gave a concentration of 0.56%. Forcomparison purposes, a similar sample has been prepared in similarconditions, but without the addition of polypropylene powder. Thislatter sample also shows a pure crystalline structure of the typeLiFePO₄.

Electrochemical Properties

The materials prepared were tested in button batteries of the CR2032type at room temperature and 80° C.

Tests at 80° C. (Polymer Electrolyte)

The materials obtained above have been tested in button batteries of theCR2032 type. The cathode was obtained by mixing together the activematerial powder with carbon black (Ketjenblack®) to ensure theelectronic exchange with the current collector, and polyethylene oxidewith a molecular weight of 400,000 is added as both a binder and anionic conductor. The proportions, by weight, are 35:9:56. Acetonitrileis added to the mixture to dissolve the ethylene polyoxide. The mixtureis homogenized and poured on a stainless steel disc of 1.7 cm². Thecathode is dried under vacuum, and transferred in a Vacuum Atmospheresglove box, under helium atmosphere (<1 vpm H₂O, O₂). A sheet of lithium(27 μm) laminated on a nickel substrate is used as the anode. Thepolymer electrolyte comprises polyethylene oxide of weight 5,000,000 andLiTFSI (lithium bis-trifluoromethanesulfonimide) in proportions ofoxygen of oxyethylene units/lithium of 20:1.

The electrochemical experiments were carried out at 80° C., thetemperature at which the ionic conductivity of the electrolyte issufficient (2×10⁻³ Scm⁻¹). The electrochemical studies are performed byslow voltammetry (20 mV·h⁻¹) controlled by a battery cycler of theMacpile® type. The batteries were charged and discharged between 3.7 and3 V.

FIG. 2 illustrates the first cycle obtained for carbonaceous andnoncarbonaceous materials prepared above. For the non-carbonaceoussample, the oxidation and reduction phenomenons extend over a widepotential range. For the carbonaceous sample, the peaks are much betterdefined on a narrow potential domain. The evolution of both materialsduring the first 5 cycles is very different (FIG. 3). For thecarbon-coated sample, the oxidation and reduction kinetics become fasterand faster, thus leading to better defined peaks (larger peak currentsand narrower peak widths). However, for the non-carbonaceous sample, thekinetics become slower and slower. The evolution of the capacity of bothsamples is illustrated in FIG. 4. For the carbonaceous sample, thecapacity exchanged is stable. It represents from 94 to 100% of thetheoretical capacity (170 mAhg⁻¹) depending on the sample. The initialcapacity of the non-carbonaceous material is around 145 mAhg⁻¹, i.e.,about 85% of the theoretical capacity. For this sample, the capacityexchanged quickly decreases. After 5 cycles, the battery has lost 20% ofits initial capacity.

The carbonaceous sample is cycled under an intentiostatic mode between3.8 and 3 V with fast charging and discharging rates. The imposedcurrents correspond to a C/1 rate, which means that all the capacity isexchanged in 1 hour. These cycling results are shown in FIG. 5. Thefirst 5 cycles are performed under a voltamperometric mode to activatethe cathode and determine its capacity. In this instance, 100% of thetheoretical capacity is exchanged during the first voltammetric cyclesand 96% during the first 80 intentiostatic cycles. Subsequently, thecapacity slowly decreases, and after 1000 cycles, 70% of the capacity(120 mAhg⁻¹) is still exchanged at this rate. The cycling in thepotentiodynamic mode performed after 950 cycles shows that in reality,89% of the initial capacity is still available at slower dischargerates. The loss of power is associated with the increase of theresistance at the lithium/polymer electrolyte interface. The parameter(capacity passed during charging)/(capacity passed during discharging)becomes erratic in appearance. This parameter C/D, shown on FIG. 5 atthe end of cycling, leads to the presumption that dendrites are formed.

Tests at Room Temperature (Liquid Electrolyte)

The LiFePO₄ coated with a carbonaceous deposit was also tested at roomtemperature. In this instance, the composite cathode is prepared bymixing the active material with carbon black and EPDM (preferablydissolved in cyclohexane) in a ratio of 85:5:10. The mixture is spreadonto a stainless steel current collector in the form of a disc of 1.7cm², dried under vacuum, and kept in a glove box under heliumatmosphere. As above, lithium is used as the anode. Both electrodes areseparated by a Celgard™ porous membrane. The electrolyte used is aLiTFSI 0.8 molal solution in gamma-butyrolactone. The voltamperogramsillustrated in FIG. 6 were obtained at room temperature under slowvoltammetry (20 mV·h⁻¹) between 3 and 3.8 V. With such configuration,the oxidation and reduction kinetics appear to be much slower than at80° C. Further, the power of the battery decreases slowly duringcycling. On the other hand, the entire theoretical capacity isaccessible (97.5% cycle 1, 99.4% cycle 5), i.e., reversibly exchangedwithout loss during cycling (5 cycles). It is not excluded that the lowpower of this battery may come from a poor permeation of the electrodeby the electrolyte, the latter being a poor wetting agent for thebinding polymer.

The example illustrates that the improvement of the material studied,because of the presence of the carbonaceous deposit at the surface ofthe particles, is reflected on the kinetics, the capacity and thecyclability. Further, its role is independent from that of the type ofcarbon black added during the preparation of composite cathodes.

Example 2

This example shows the formation of a conductive carbonaceous depositfrom a hydrocarbon gas. The synthesis described in Example 1 for thepreparation of lithium iron phosphate is repeated without addingpolypropylene powder, and by replacing the thermal treatment inertatmosphere with a mixture of 1% propene in nitrogen. During the thermaltreatment, propene decomposes to form a carbon deposit on the materialbeing synthesized. The resulting sample obtained contains 2.5% ofcarbon, as determined by chemical analysis. Cyclic voltammetry isperformed on this sample under the conditions described in Example 1,and shows the important activation phenomenon during the first cycles(see FIG. 6). The improvement in redox kinetics is accompanied in thisinstance by an increase of the capacity reversibly exchanged. Asmeasured during the discharge step, the initial capacity of the LiFePO₄sample prepared represents 77% of the theoretical capacity, taking intoaccount the 2.5% electrochemically inactive carbon. After 5 cycles, thecapacity reaches 91.4%. The activation phenomenon observed is linked tothe thickness of the carbon layer, which may be porous, coating theparticles and capable of slowing the diffusion of the cations.

The following examples 3-5 illustrate the treatment of the complexoxide, namely the lithium iron phosphate (LiFePO₄), prepared thermallyand independently in order to obtain a conductive carbonaceous coating.

Example 3

The tryphilite sample LiFePO₄ prepared above is analyzed. Its masscomposition is: Fe: 34.6%, Li: 4.2%, P: 19.2%, which represents a 5%difference with respect to the stoichiometry.

The powder to be treated is impregnated with an aqueous solution ofcommercial sucrose and dried. The amount of solution is selected tocorrespond to 10% of the weight of sucrose with respect to the weight ofthe material to be treated. Water is completely evaporated underagitation to obtain a homogeneous distribution. The use of sugarrepresents a preferred embodiment because it melts before beingcarbonized, thereby providing a good coating of the particles. Itsrelatively low carbon yield after pyrolysis is compensated by its lowcost.

The thermal treatments are performed at 700° C. under argon atmosphere.The temperature is maintained for 3 hours. Elemental analysis shows thatthis product contains 1.3% by weight of carbon. Such thermal treatmentleads to a black powder giving an electronic conductivity measurablewith a simple commercial ohm-meter. Its electroactivity, as measured onthe 1^(st) (FIG. 8) and 5^(th) (FIG. 9) charge-discharge cycle, is 155.9mAhg⁻¹ and 149.8 mAhg⁻¹ respectively, which is 91.7% and 88.1% of thetheoretical value. These values are to be compared with that of theproduct not coated with the carbon deposit, that has only 64%electroactivity. After 5 cycles, this value fades to 37.9% (FIG. 10).

Example 4

Cellulose acetate is added to the phosphate LiFePO₄ of Example 3 as aprecursor of the carbon coating. This polymer is known to decompose withhigh carbonization yields, on the order of 24%. It decomposes between200 and 400° C. Above this temperature, the amorphous carbon rearrangesto give a graphite-type structure that favors coherent and highlyconductive carbon deposits.

Cellulose acetate is dissolved in acetone in a ratio corresponding to 5%by weight of the material to be treated, and dried before proceeding asabove. The carbon concentration of the final product is 1.5%. Thethermal treatment leads, in a similar manner, to a black powder havingsurface electronic conductivity. Its electroactivity, as measured on the1^(st) (FIG. 8) and 5^(th) (FIG. 9) charge-discharge cycles, is 152.6mAhg⁻¹ and 150.2 mAhg⁻¹ respectively, which is 89.8% and 88.3% of thetheoretical value. This value is to be compared with that of the productnot coated with the carbon deposit, that has only 64% electroactivity.After 5 cycles, this value fades to 37.9% (FIG. 10).

Example 5

Perylene and its derivatives are known to lead, after pyrolysis, tographitic-type carbons because of the existence of condensed cycles inthe starting molecule. In particular, the perylene-tetracarboxylic acidanhydride decomposes above 560° C. and provides a thin carbon layersufficient to cover the particle surface. However, this product shows apoor solubility, and their intimate mixture with the complex oxide, herealso LiFePO₄ of Example 3, is difficult to embody. To solve thisproblem, a polymer containing perylene groups separated with an ethylenepolyoxide chain has been prepared in a first step. The oxyethylenesegments are selected to be sufficiently long to act as solubilizingagents for the aromatic groups in the usual organic solvents. Therefore,commercial 3,4,9,10-perylenetetracarboxylic acid anhydride (Aldrich) isreacted with Jeffamine 600 (Hunstmann) at high temperatures, accordingto the following reaction:

whereinR=—[CH(CH₃)CH₂O—]_(p)(CH₂CH₂O—)_(q)[CH₂—CH(CH)₃O]_(p-1)CH₂—CH(CH)₃—1≦p≦2; 10≦n≦14.The synthesis is completed within 48 hours in dimethylacetamide underreflux (166° C.). The polymer formed is precipitated in water, and asolid-liquid separation is carried out. It is purified by dissolution inacetone, followed by re-precipitation in ether. The process allows theremoval of unreacted starting materials, as well as low mass products.The powder is finally dried.

Carbonization yield of this product is on the order of 20%. The polymeris dissolved in dichloromethane in a ratio corresponding to 5% of theweight of the material to be treated before proceeding as describedabove in Examples 3 and 4. The carbon content of the final product is1%. The thermal treatment leads, as described above, to a blackconductive powder. Its electroactivity, as measured on the 1^(st) (FIG.8) and 5^(th) (FIG. 9) charge-discharge cycles, is 148.6 mAhg⁻¹ and146.9 mAhg⁻¹ respectively, which is 87.4% and 86.4% of the theoreticalvalue. This value is to be compared with that of the product not coatedwith the carbon deposit, that has only 64% electroactivity. After 5cycles, this value fades to 37.9% (FIG. 10).

Example 6

This example illustrates the use of an elimination reaction from apolymer to form a carbonaceous deposit according to the invention.

Ferric iron sulfate (Fe₂(SO₄)₃) with a “Nasicon” orthorhombic structurewas obtained from commercial hydrated iron (III) sulfate (Aldrich) bydehydration at 450° C. under vacuum. With cooling, and under stirring,the powder suspended in hexane was lithiated with stoichiometric 2Mbutyl lithium to reach the composition Li_(1.5)Fe₂(SO₄)₃. 20 g of theresulting white powder were slurried in 100 mL acetone and 2.2 g ofpoly(vinylidene bromide) (—CH₂CBr₂)_(n)— were added and the mixture wastreated for 12 hours in a ball mill with alumina balls. The suspensionthus obtained was dried in a rotary evaporator and crushed as coarsepowder in a mortar. The solid was treated with 3 g ofdiazabicyclo[5.4.0]unde-7-cene (DBU) in acetonitrile under reflux forthree hours. The black powder thus obtained was filtered to eliminatethe resulting amine bromide and excess reagent, rinsed with acetonitrileand dried under vacuum at 60° C. Further annealing of the carbonaceousdeposit was performed under oxygen-free argon (<1 ppm) at 400° C. forthree hours.

The material coated with the carbonaceous material was tested forelectrochemical activity in a lithium cell with a lithium metalelectrode, 1 molar lithium bis-(trifluoromethanesulfonimide) in 50:50ethylene carbonate-dimethoxymethane mixture as electrolyte immobilizedin a 25 μm microporous polypropylene separator. The cathode was obtainedfrom the prepared redox material mixed with Ketjenblack® and slurried ina solution of ethylene-propylene-diene polymer (Aldrich), the ratio ofsolids content being 85:10:5. The cathode mix was spread on an expandedaluminium metal grid and pressed at 1 ton cm⁻² to a resulting thicknessof 230 μm. The button cell assembly was charged (the tested materialbeing the anode) at 1 mAcm⁻² between the cut-off potentials of 2.8 and3.9 V. The material capacity is 120 mAhg⁻¹, corresponding to 89% oftheoretical value. The average potential was obtained at 3.6 V vs.Li⁺:Li^(o).

Example 7

This example illustrates the use of a nitrogen-containing compound as anelectrode material.

Powdered manganous oxide (MnO) and lithium nitride, both commercial(Aldrich), were mixed in a dry box under helium in a 1:1 molar ratio.The reactants were put in a glassy carbon crucible and treated underoxygen-free nitrogen (<1 vpm) at 800° C. 12 g of the resultingoxynitride with an antifluorite structure Li₃MnNO were added to 0.7 g ofmicrometer size polyethylene powder and ball milled under helium in apolyethylene jar with dry heptane as the dispersing agent and 20 mg ofBrij™ 35 (ICI) as the surfactant. The filtered mix was then treatedunder a flow of oxygen-free nitrogen in a furnace at 750° C. to ensuredecomposition of the polyethylene into carbon.

The carbon-coated electrode material appears as a black powder rapidlyhydrolyzed in moist air. All subsequent handling was carried out in adry box wherein a cell similar to that of Example 6 was constructed andtested for electrochemical activity of the prepared material. Theelectrolyte in this case is a mixture of commercial tetraethylsulfamide(Fluka) and dioxolane in a 40:60 volume ratio. Both solvents werepurified by distillation over sodium hydride (under 10 torrs reducedpressure for the sulfamide). Lithium bis-(trifluoromethanesulfonimide)(LiTFSI) is added to the solvent mixture to form a 0.85 molar solution.Similar to the set-up of Example 6, the cell comprises a lithium metalelectrode, the electrolyte immobilized in a 25 μm porous polypropyleneseparator and the material processed in a way similar to that of Example6.

The cathode is obtained from the prepared redox material mixed withKetjenblack® and slurried in a solution of ethylene-propylene-dienepolymer, the ratio of solids content being 90:5:5. The cathode mix ispressed on an expanded copper metal grid at 1 ton cm⁻² with a resultingthickness of 125 μm. The button cell assembly is charged at 0.5 mAcm⁻²(the oxynitride being the anode) between the cut-off potentials of 0.9and 1.8 V. The material's capacity was 370 mAhg⁻¹, i.e., 70% of thetheoretical value for two electrons per formula unit. The averagepotential is found at 1.1 V vs. Li⁺:Li^(o). The material is suited foruse as a negative electrode material in lithium-ion type batteries. Anexperimental cell of this type has been constructed with the electrodematerial on a copper metal grid similar to that tested previously and apositive electrode material obtained by chemical delithiation of thelithium iron phosphate of Example 1 by bromine in acetonitrile. The iron(III) phosphate obtained was pressed onto an aluminium grid to form thepositive electrode and the 0.85 M LiTFSI tetraethylsulfamide/dioxolanesolution used as an electrolyte. The average voltage of such cell is 2.1V and its energy density, based on the weight of the active materials,is 240 Wh/Kg.

Example 8

Lithium vanadium (III) phosphosilicate(Li_(3.5)V₂(PO₄)_(2.5)(SiO₄)_(0.5)), having a “Nasicon” structure wasprepared in the following manner:

Lithium carbonate (13.85 g), lithium silicate Li₂SiO₃, (6.74 g),dihydrogen ammonium phosphate (43.2 g) and ammonium vanadate (35.1 g)were mixed with 250 mL of ethylmethylketone and treated in a ball millwith alumina balls in a thick-walled polyethylene jar for 3 days. Theresulting slurry was filtered, dried and treated in a tubular furnaceunder a 10% hydrogen in nitrogen gas flow at 600° C. for 12 hours. Aftercooling, 10 g of the resulting powder were introduced in a planetaryball mill with tungsten carbide balls. The resulting powder was added toa solution of the polyaromatic polymer prepared in Example 5(polyoxyethylene-co-perylenetetracarboxylicdimide 0.8 g in 5 mLacetone), well homogenized, and the solvent was evaporated.

The red-brown powder was thermolyzed in a stream of oxygen-free argon at700° C. for 2 hours, leaving after cooling a black powder with ameasurable surface conductivity. The material coated with thecarbonaceous material was tested for electrochemical activity in alithium-ion cell with a natural graphite electrode (NG7) coated on acopper current collector and corresponding to 24 mg/cm², 1 molar lithiumhexafluorophosphate in 50:50 ethylene carbonate dimethylcarbonatemixture as electrolyte immobilized in a 25 μm microporous polypropyleneseparator. The cathode was obtained from the lithium vanadiumphosphosilicate mixed with Ketjenblack® and slurried in a solution ofvinylidenefluoride-hexafluoropropene copolymer in acetone, the ratio ofsolids content being 85:10:5. The cathode mix was spread on an expandedaluminium metal grid and pressed at 1 ton cm⁻² to a resulting thicknessof 190 μm corresponding to an active material loading of 35 mg/cm². Thebutton cell assembly was charged (the tested material being the anode)at 1 mAcm⁻² between the cut-off potentials of 0 and 4.1 V. The capacityof the carbon coated material was 184 mAhg⁻¹, corresponding to 78% ofthe theoretical value (3.5 lithium per unit formula), slowly fading withcycling. In a comparative test, a similar cell constructed using theuncoated material, as obtained after milling the heat treated inorganicprecursor but omitting the addition of the perylene polymer, shows acapacity of 105 mAhg⁻¹, rapidly fading with cycling.

Example 9

This example illustrates the formation of a carbonaceous coatingsimultaneous to a variation of the alkali metal content of the redoxmaterial.

13.54 g of commercial iron (III) fluoride (Aldrich), 1.8 g of thelithium salt of hexa-2,4-dyine dicarboxylic acid are ball milled in athick-walled polyethylene jar with alumina balls, in the presence of 100mL of acetonitrile. After 12 hours, the resulting slurry was filteredand the dried powder was treated under a stream of dry, oxygen-freenitrogen in a tubular furnace at 700° C. for three hours. The resultingblack powder contained from elemental analysis: Fe: 47%, F: 46%, Li:1.18%, C: 3.5%, corresponding to the formula Li_(0.2)FeF₃C_(0.35). Theelectrode material was tested for its capacity in a cell similar to thatof Example 6 with the difference being that the cell is first tested ondischarge (the electrode material as cathode), and then recharged. Thecut-off voltages were chosen between 2.8 and 3.7 V. The experimentalcapacity on the first cycle was 190 mAhg⁻¹, corresponding to 83% of thetheoretical value. For comparison, a cell with FeF₃ as the electrodematerial and no carbonaceous coating has a theoretical capacity of 246mAhg⁻¹. In practice, the first discharge cycle obtained in similarconditions to the material of the invention is 137 mAhg⁻¹.

Example 10

This example also illustrates the formation of a carbonaceous coatingsimultaneous to a variation of the alkali metal content of the redoxmaterial.

Commercial polyacrylic acid of molecular weight 15,000 was dissolved as10% solution in water/methanol mixture and titrated with lithiumhydroxide to a pH of 7. 4 μL of this solution were dried in the crucibleof a thermogravimetry air at 80° C. to evaporate the water/methanol. Theheating was then continued to 500° C., showing a residue of 0.1895 mg ofcalcination residue as lithium carbonate.

18.68 g of commercial iron (III) phosphate dihydrate, (Aldrich), 8.15 glithium oxalate (Aldrich), 39 mL of the lithium polyacrylate solution,80 mL of acetone and 40 mL of 2,2-dimethoxy acetone as water scavengerwere ball milled in a thick-walled polyethylene jar with alumina balls.After 24 hours, the resulting slurry was filtered and dried. Theresulting powder was treated under a stream of dry, oxygen-free nitrogenin a tubular furnace at 700° C. for three hours, resulting in a blackishpowder. The resulting product had the following elemental analysis: Fe:34%, P: 18.8%, Li: 4.4%, C: 3.2%. The X-ray analysis confirmed theexistence of pure triphilite LiFePO₄ as the sole crystalline component.The electrode material was tested for its capacity in a cell similar tothat of Example 1 with a PEO electrolyte, and then recharged. Thecut-off voltages were chosen between 2.8 and 3.7 V. The experimentalcapacity on the first cycle was 135 mAhg⁻¹, corresponding to 77% of thetheoretical value, increasing to 156 mAhg⁻¹ (89%) while the peakdefinition improved with further cycling. 80% of this capacity isaccessible in the potential range 3.3-3.6 V vs. Li⁺:Li^(o).

Example 11

The compound LiCo_(0.75)Mn_(0.25)PO₄ was prepared from intimately groundcobalt oxalate dihydrate, manganese oxalate dihydrate and dihydrogenammonium phosphate by firing in air at 850° C. for 10 hours. Theresulting mauve powder was ball milled in a planetary mill with tungstencarbide balls to an average grain size of 4 μm. 10 g of this complexphosphate were triturated in a mortar with 10 mL of 6% solution of theperylene polymer of Example 5 in methyl formate. The solvent rapidlyevaporated. The resulting powder was treated under a stream of dry,oxygen-free argon in a tubular furnace at 740° C. for three hours,resulting in a black powder. The electrochemical activity of the cellwas tested in a lithium-ion cell similar to that of Example 6. Theelectrolyte was, in this case, lithium bis-fluoromethanesulfonimide(Li[FSO₂]₂N) dissolved at a concentration of 1M in theoxidation-resistant solvent dimethylamino-trifluoroethyl sulfamate(CF₃CH₂OSO₂N(CH₃)₂). When initially charged, the cell showed a capacityof 145 mAhg⁻¹ in the voltage window 4.2-4.95 V vs. Li⁺:Li^(o). Thebattery could be cycled for 50 deep charge-discharge cycles with lessthan 10% decline in capacity, showing the resistance of the electrolyteto high potentials.

Example 12

The compound Li₂MnSiO₄ was prepared by calcining the gel resulting fromthe action of a stoichiometric mixture of lithium acetate dihydrate,manganese acetate tetrahydrate and tetraethoxysilane in a 80:20 ethanolwater mixture. The gel was dried in an oven at 80° C. for 48 hours,powdered and calcined under air at 800° C. 3.28 g of the resultingsilicate and 12.62 g of lithium iron phosphate from Example 3 were ballmilled in a planetary mill similar to that of Example 11, and the powderwas treated at 800° C. under a stream of dry, oxygen-free argon in atubular furnace at 740° C. for 6 hours. The complex oxide obtained aftercooling has the formula Li_(1.2)Fe_(0.8)Mn_(0.2)P_(0.8)Si_(0.2)O₄. Thepowder was moistened with 3 mL of a 2% solution of cobalt acetate, thendried. The powder was treated in the same tubular furnace at 500° C.under a flow of 1 mL/s of 10% carbon monoxide in nitrogen for two hours.After cooling, the resulting black powder was tested for electrochemicalactivity in conditions similar to those of Example 1. With a PEOelectrolyte at 80° C., the capacity was measured from the cyclicvoltamogram curve at 185 mAhg⁻¹ (88% of theory) between the cut-offvoltages of 2.8 and 3.9 V vs. Li⁺:Li^(o). The uncoated material, testedin similar conditions, has a specific capacity of 105 mAhg⁻¹.

Example 13

Under argon, 3 g of lithium iron phosphate from Example 3 was suspendedin 50 mL acetonitrile to which was added 0.5 g ofhexachlorocyclopentadiene and 10 mg oftetrakis(triphenylphosphine)nickel (0). Under vigorous stirring, 1.4 mLof tetrakis(dimethylamino)ethylene was added dropwise at roomtemperature. The solution turned blue, and after more reducing agent wasadded, black. The reaction was left under stirring for 24 hours aftercompletion of the addition. The resulting black precipitate wasfiltered, washed with ethanol and dried under vacuum. Annealing of thecarbon deposit was performed at 400° C. under a flow of oxygen-free gasfor 3 hours. The resulting black powder was tested for electrochemicalactivity in conditions similar to those of Example 1. The measuredcapacity between the cut-off voltages of 2.9 and 3.7 V vs. Li⁺:Li^(o)was found experimentally at 160 mAhg⁻¹ (91% of theory). The uncoatedmaterial has a specific capacity of 112 mAhg⁻¹ in the same experimentalconditions.

Example 14

The spinel compound Li_(3.5)Mg_(0.5)Ti₄O₁₂ was prepared by sol-geltechnique using titanium tetra(isopropoxide) (28.42 g), lithium acetatedihydrate (35.7 g) and magnesium acetate tetrahydrate (10.7 g) in 300 mL80:20 isopropanol-water. The resulting white gel was dried in an oven at80° C. and calcined at 800° C. in air for 3 hours, then under 10%hydrogen in argon at 850° C. for 5 hours. 10 g of the resulting bluepowder were mixed with 12 mL of a 13 wt % solution of the celluloseacetate in acetone. The paste was dried and the polymer carbonized inthe conditions of Example 4 under inert atmosphere at 700° C.

The positive electrode of an electrochemical super capacitor was builtin the following manner. 5 g of carbon-coated LiFePO₄ from Example 3, 5g of Norit® activated carbon, 4 g of graphite powder (2 μm diameter), 3g of chopped aluminium fibers (20 μm long and 5 mm diameter), 9 g ofanthracene powder (10 μm) as a pore former and 6 g of polyacrylonitrilewere mixed in dimethylformamide wherein the polymer dissolved. Theslurry was homogenized and coated onto aluminium foil (25 μm) and thesolvent was evaporated. The coating was then slowly brought to 380° C.under nitrogen atmosphere. The anthracene evaporated to leave ahomogeneous porosity in the material and the acrylonitrile underwentthermal cyclization to a conductive polymer consisting of fused pyridinerings. The thickness of the resulting layer is 75 μm.

A similar coating is done for the negative electrode with a slurry whereLiFePO₄ is replaced with the coated spinel as prepared above. The supercapacitor assembly is obtained by placing the two prepared electrodesface to face, separated by a 10 μm-thick polypropylene separator soakedin 1 molar LiTFSI in acetonitrile/dimethoxyethane mixture (50:50). Thedevice can be charged at 30 mAcm⁻² and 2.5 V and delivers a specificpower of 3 kW/L⁻¹ at 1.8 V.

Example 15

A light modulating device (electrochromic window) was constructed in thefollowing manner.

LiFePO₄ from Example 3 was ball milled in a high energy mill toparticles of an average size of 120 nm. 2 g of the powder were mixedwith 1 mL of a 2 wt % solution of the perylene-co-polyoxyethylenepolymer of Example 5 in methyl formate. The paste was triturated toensure uniform distribution of the polymer at the surface of theparticles, and the solvent was evaporated. The dry powder was treatedunder a stream of dry, oxygen-free nitrogen in a tubular furnace at 700°C. for three hours to yield a light gray powder.

1 g of the carbon-coated powder was slurried in a solution of 1.2 gpolyethyleneoxide-co-(2-methylene)propane-1,3-diyl prepared according toJ. Electrochem. Soc., 1994, 141(7), 1915 with ethylene oxide segments ofmolecular weight 1000, 280 mg of LiTFSI and 15 mg of diphenylbenzyldimethyl acetal as photoinitiator in 10 mL of acetonitrile. The solutionwas coated using the doctor blade process onto an indium-tin oxide (ITO)covered glass (20 S⁻¹□) to a thickness of 8 μm. After evaporation of thesolvent, the polymer was cured with a 254 nm UV light (200 mWcm⁻²) for 3minutes.

Tungsten trioxide was deposited by thermal evaporation onto another ITOcovered glass to a thickness of 340 nm. The device assembly was done byapplying a layer of a polyethylene oxide (120 μm) electrolyte withLiTFSI in an oxygen (polymer) to salt ratio of 12, previously coated ona polypropylene foil and applied to the WO₃-coated electrode using theadhesive transfer technology. The two glass electrodes were pressedtogether to form the electrochemical chain:

glass/ITO/WO₃/PEO-LiTFSI/LiFePO₄ composite electrode/ITO/glass

The device turned blue in 30 seconds upon application of a voltage (1.5V, LiFePO₄ side being the anode) and bleached on reversal of thevoltage. The light transmission is modulated from 85% (bleached state)to 20% (colored state).

While the invention has been described in connection with specificembodiments thereof, it will be understood that it is capable of furthermodifications, and this application is intended to cover any variations,uses or adaptations of the invention following, in general, theprinciples of the invention, and including such departures from thepresent description as come within known or customary practice withinthe art to which the invention pertains, and as may be applied to theessential features hereinbefore set forth, and as follows in the scopeof the appended claims.

1-38. (canceled)
 39. An electrode material comprising: a particle ofelectroactive material comprising: at least one complex oxide of theformula A_(a)M_(m)Z_(z)O_(o)N_(n)F_(f), wherein: A comprises at leastone alkali metal; M comprises at least one transition metal; Z comprisesat least one non-metal; O is oxygen; N is nitrogen; F is fluorine;wherein the coefficients a, m and z>0; wherein at least one of o, n andf>0; and a solid polymer comprising between 60 molar % and 100 molar %carbon (C) and having an electronic conductivity of at least 10⁻⁶ S/cm,wherein the solid polymer is coated on the surface of the electroactivematerial, wherein the particle retains at least approximately 85% of itstheoretical capacity after at least five cycles in an electrochemicalcell cycled at 20 mV/h.
 40. The electrode material of claim 39, whereinthe solid polymer has an electronic conductivity of at least 10⁻⁴ S/cm.41. The electrode material of claim 39, wherein the solid polymerfurther comprises hydrogen (H), oxygen (O), or nitrogen (N).
 42. Theelectrode material of claim 39, wherein M is selected from the groupconsisting of Fe²⁺, Mn²⁺, V²⁺, V³⁺, Ti²⁺, Ti³⁺, Mo³⁺, Mo⁴⁺, Nb³⁺, Nb⁴⁺,and W⁴⁺.
 43. The electrode material of claim 39, wherein the electrodematerial particle comprises between 10% to 70% solid polymer byelectrode material particle volume.
 44. The electrode material of claim43, wherein the alkali metal comprises Li, Na, or K.
 45. The electrodematerial of claim 39, wherein the electrode material further comprisesan additional conductive carbon material in the form of a fine power orfiber.
 46. The electrode material of claim 45, wherein the additionalconductive carbon material comprises carbon black or carbon fibers. 47.The electrode material of claim 45, wherein the electrode material is inthe form of an electrode material particle comprising between 0.5% to10% conductive carbon material by electrode material particle volume.48. The electrode material of claim 39, wherein the particle retains atleast approximately 70% of its theoretical capacity after at least onethousand cycles in an electrochemical cell cycled at 20 mV/h.
 49. Asecondary battery comprising an electrode material comprising: aparticle of electroactive material comprising: at least one complexoxide of the formula A_(a)M_(m)Z_(z)O_(o)N_(n)F_(f), wherein: Acomprises at least one alkali metal; M comprises at least one transitionmetal; Z comprises at least one non-metal; O is oxygen; N is nitrogen; Fis fluorine; wherein the coefficients a, m and z>0; wherein at least oneof o, n and f>0; and a solid polymer comprising between 60 molar % and100 molar % carbon (C) and having an electronic conductivity of at least10⁻⁶ S/cm, wherein the solid polymer is coated on the surface of theelectroactive material, wherein the particle retains at leastapproximately 85% of its theoretical capacity after at least five cyclesin an electrochemical cell cycled at 20 mV/h.
 50. The secondary batteryof claim 49, wherein the solid polymer has an electronic conductivity ofat least 10⁻⁴ S/cm.
 51. The secondary battery of claim 49, wherein thesolid polymer further comprises hydrogen (H), oxygen (O), or nitrogen(N).
 52. The secondary battery of claim 49, wherein M is selected fromthe group consisting of Fe²⁺, Mn²⁺, V²⁺, V³⁺, Ti²⁺, Ti³⁺, Mo³⁺, Mo⁴⁺,Nb³⁺, Nb⁴⁺, and W⁴⁺.
 53. The secondary battery of claim 49, wherein theelectrode material particle comprises between 10% to 70% solid polymerby electrode material particle volume.
 54. The secondary battery ofclaim 53, wherein the alkali metal comprises Li, Na, or K.
 55. Thesecondary battery of claim 49, wherein the electrode material furthercomprises an additional conductive carbon material in the form of a finepower or fiber.
 56. The secondary battery of claim 55, wherein theadditional conductive carbon material comprises carbon black or carbonfibers.
 57. The secondary battery of claim 55, wherein the electrodematerial is in the form of an electrode material particle comprisingbetween 0.5% to 10% conductive carbon material by electrode materialparticle volume.
 58. The secondary battery of claim 49, furthercomprising the electrode material deposited on and aluminum (Al) acurrent collector.
 59. The secondary battery of claim 49, furthercomprising a polymer electrolyte.
 60. The secondary battery of claim 49,wherein the particle retains at least approximately 70% of itstheoretical capacity after at least one thousand cycles of the secondarybattery at 20 mV/h.